OM-246 691F 2015 06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Wire Feeder MigMatic 220/250 Base/DX CE Visit our website at www.millerwelds.com OWNER S MANUAL File: MIG (GMAW)
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don t have time to do it any other way. That s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.
TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING... 1 1-1. Symbol Usage... 1 1-2. Arc Welding Hazards... 1 1-3. Additional Symbols For Installation, Operation, And Maintenance... 3 1-4. California Proposition 65 Warnings... 4 1-5. Principal Safety Standards... 4 1-6. EMF Information... 4 SECTION 2 DEFINITIONS... 5 2-1. Additional Safety Symbols And Definitions... 5 2-2. Miscellaneous Symbols And Definitions... 7 SECTION 3 SPECIFICATIONS... 8 3-1. Serial Number And Rating Label Location... 8 3-2. Specifications... 8 3-3. Environmental Specifications... 8 3-4. Duty Cycle And Overheating... 9 3-5. Volt-Ampere Curves... 9 SECTION 4 INSTALLATON... 10 4-1. Selecting A Location... 10 4-2. Installing Gas Supply... 11 4-3. Installing Wire Spool And Adjusting Hub Tension... 12 4-4. Positioning Jumper Links (230/400V 3-Phase Models)... 13 4-5. Electrical Service Guide... 14 4-6. Connecting Input Power (1-Phase and 3-Phase)... 16 4-7. Installing Drive Rolls And Wire Guide... 20 4-8. Threading Welding Wire And Adjusting Pressure Roll Tension... 21 SECTION 5 OPERATION... 22 5-1. Controls For MigMatic 220/250... 22 5-2. Burnback And Spot Weld Timer Controls... 22 5-3. Controls For MigMatic 220 DX / 250 DX... 23 5-4. Burnback And Spot Weld Timer Controls... 23 5-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only)... 24 5-6. Welding Power Source Setup Menu (DX Models Only)... 25 5-7. Trigger Mode Selection (DX Models Only)... 26 5-8. Spool Gun Mode (DX Models Only)... 26 5-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only)... 27 5-10. Welding Wire Type Selection For Synergic MIG (DX Models Only)... 27 5-11. Gas Selection For Synergic MIG (DX Models Only)... 27 5-12. Selecting Manual MIG Welding (DX Models Only)... 28 5-13. Selecting Synergic MIG Welding (DX Models Only)... 29 SECTION 6 MAINTENANCE &TROUBLESHOOTING... 30 6-1. Routine Maintenance... 30 6-2. Circuit Breaker CB1... 30 6-3. Unit Overload... 30 6-4. Troubleshooting... 31 SECTION 7 ELECTRICAL DIAGRAMS... 32 SECTION 8 PARTS LIST... 36 WARRANTY
DECLARATION OF CONFORMITY for European Community (CE marked) products. ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number MIGMATIC 220, 230VAC 029015520 MIGMATIC 220 DX, 230VAC 029015521 MIGMATIC 250 230/400VAC 029015524 MIGMATIC 250 DX, 230/400VAC 029015525 Council Directives: 2006/95/EC Low Voltage 2004/108/EC Electromagnetic Compatibility 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards: IEC 60974-1:2012 Arc Welding Equipment Part 1: Welding Power Sources IEC 60974-5:2007 Arc Welding Equipment Part 5: Wire Feeders IEC 60974-10:2007 Arc Welding Equipment Part 10: Electromagnetic Compatibility Requirements EU Signatory: June 24 th, 2015 Massimigliano Lavarini Date of Declaration ITW WELDING ITALY PRODUCTION MANAGER 956 172 214
7 SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING som 2013 09 Protect yourself and others from injury read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install, ground, and operate this equipment according to its Owner s Manual and national, state, and local codes. Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment in damp or wet locations. SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. OM-246 691 Page 1
OM-246 691 Page 2 FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. Wear body protection made from durable, flame resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear body protection made from durable, flame resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Read and understand the Safety Data Sheets (SDSs) and the manufacturer s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. FLYING METAL or DIRT can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94 110) when manually lifting heavy parts or equipment. OVERUSE can cause OVERHEATING READ INSTRUCTIONS. Read and follow all labels and the Owner s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner s Manuals, industry standards, and national, state, and local codes. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. H.F. RADIATION can cause interference. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires keep flammables away. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. MOVING PARTS can injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure. Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-246 691 Page 3
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/niosh). 1-6. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. OM-246 691 Page 4
SECTION 2 DEFINITIONS 2-1. Additional Safety Symbols And Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012 05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012 05 Protect yourself from electric shock by insulating yourself from work and ground. Safe3 2012 05 Disconnect input plug or power before working on machine. Safe5 2012 05 Keep your head out of the fumes. Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes. Safe8 2012 05 Use ventilating fan to remove fumes. Safe10 2012 05 Keep flammables away from welding. Do not weld near flammables. Safe12 2012 05 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012 05 Do not remove or paint over (cover) the label. Safe20 2012 05 OM-246 691 Page 5
Do not weld on drums or any closed containers. Safe16 2012 05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012 05 Disconnect input plug or power before working on machine. Safe30 2012 05 ÍÍ Read Owner s Manual and inside labels for connection points and procedures. Safe67 2012 06? V? A Consult rating label for input power requirements. Safe34 2012 05 Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away. <10 Falling unit can cause injury. Do not move or operate unit where it could tip. Safe33 2012 05 Safe53 2012 05 Move jumper links as shown on inside label to match input voltage at job site. Include extra length in grounding conductor and connect grounding conductor first. Connect line input conductors as shown on inside label. Double-check all connections, jumper link positions, and input voltage before applying power. 3 1 Safe49 2012 05 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Safe38 2012 05 Become trained and read the instructions before working on the machine or welding. Safe40 2012 05 OM-246 691 Page 6
2-2. Miscellaneous Symbols And Definitions A V Amperage Volts I1max I1eff Rated Maximum Supply Current Maximum Effective Supply Current Gas Output Gas Type Alternating Current (AC) U 2 Conventional Load Voltage Voltage Input Direct Current (DC) Remote On I 2 X Rated Welding Current Duty Cycle Percent Hz Wire Feed Spool Gun Wire Feed Hertz Off Protective Earth (Ground) U 0 IP Rated No Load Voltage (OCV) Degree Of Protection Read Operator s Manual Wire Type Line Connection Circuit Breaker Diameter Three Phase Three Phase Transformer Rectifier t Spot Weld Time Single Phase Two-Step Trigger Operation Wire Burnback Control Gas Metal Arc Welding (GMAW) Four-Step Trigger Operation Wire Run-In Speed Control U 1 Primary Voltage Gas Input OM-246 691 Page 7
SECTION 3 SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-2. Specifications Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-5 and 4-6 for information on connecting input power. Model 220 230 VAC 50/60 Hz Rated Output 100% 60% 20% 90 A 18.5 V Wire feed speed range 1.3 mpm to 20 mpm. Model 250 230/400 VAC 50/60 Hz 116 A 19.8 V Rated Output 200 A 24.0 V 100% 60% 35% 145 A 21.0 V Wire feed speed range 1.3 mpm to 20 mpm. 190 A 23.0 V 250 A 26.5 V Max. Open Circuit Voltage Max. Open Circuit Voltage Amperage Range DC Dimension (mm) Weight (kg) 40.2 30-200 A 480 x 712 x 920 66 Net Amperage Range DC Dimension (mm) Weight (kg) 43.0 V 30-250 A 480 x 712 x 920 73 Net 3-3. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered. Operating Temperature Range -10 to 40 C (14 to 104 F) IP23S 2014 06 B. Information On Electromagnetic Fields (EMF)! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974 1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person. Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding circuit may not be a major contributor to the EMF. See the Owner s Manuals for all components of the welding circuit for additional EMF exposure information. The EMF assessment on this equipment was conducted at 0.5 meter. At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values. ce-emf 1 2010-10 C. Information On Electromagnetic Compatibility (EMC)! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. This equipment complies with IEC 61000-3-11 and IEC 61000-3-12. OM-246 691 Page 8 ce-emc 4 2014-07
3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. NOTICE Exceeding duty cycle can damage unit and void warranty. % DUTY CYCLE 35% Duty Cycle At 250 Amperes 100% Duty Cycle At 145 Amperes 3-1/2 Minutes Welding 6-1/2 Minutes Resting Overheating 0 Continuous Welding A or V Minutes 15 OR Reduce Duty Cycle sduty1 5/95 3-5. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. Model 220 Model 250 MAX MIN OM-246 691 Page 9
SECTION 4 INSTALLATON 4-1. Selecting A Location! Do not move or operate unit where it could tip.! Do not move or operate unit where it could tip. 1 Line Disconnect Device Locate unit near correct input power supply.! Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20. Airflow Distance Requirements 1 460 mm (18 in.) 460 mm (18 in.) OM-246 691 Page 10
4-2. Installing Gas Supply 1 Argon Gas Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection 3 Flow Adjust Typical flow rate is 0.9 liters per minute. Check wire manufacturer s recommended flow rate. This flow gauge can be adjusted between 2.36 and 11.8 liters per minute. OR 2 3 CO 2 Gas Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A OM-246 691 Page 11
4-3. Installing Wire Spool And Adjusting Hub Tension 1 Spacers Use only for 5Kg spool. Hub Assembly 1 15 Kg Wire Spool Assembly 5 Kg Wire Spool Assembly Tools Needed: Ref. D2 OM-246 691 Page 12
4-4. Positioning Jumper Links (230/400V 3-Phase Models)! Disconnect and lockout/tagout input power before installing or moving jumper links. Check input voltage available at site. 1 Jumper Link Label Check label only one is on unit. 2 Jumper Links Move jumper links to match input voltage. Close and secure access door. 230 Volts 400 Volts 400 Volts 230 Volts 956142718_3-5 OM-246 691 Page 13
4-5. Electrical Service Guide Elec Serv 2014 01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Power cord supplied with unit is sized for 230 volt operation. Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations. MigMatic Model 220 50/60 Hz Single Phase 250 50/60 Hz Three Phase Input Voltage (V) 230 230 400 Input Amperes (A) At Rated Output 34 28 16 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay Fuses 2 40 30 15 Normal Operating Fuses 3 50 40 25 Min Input Conductor Size In mm2 (AWG) 4 10 (8) 6 (10) 4 (12) Max Recommended Input Conductor Length In Meters (Feet) 41 (134) 38 (124) 69 (226) Min Grounding Conductor Size In mm2 (AWG) 4 6 (10) 6 (10) 4 (12) Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Time-Delay fuses are UL class RK5. See UL 248. 3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Notes OM-246 691 Page 14
Notes OM-246 691 Page 15
4-6. Connecting Input Power (1-Phase and 3-Phase) A. 1-Phase 1 3 =GND/PE Earth Ground 7 2 4 6 L1 L2 5 1 Tools Needed: input4 2012 05 Ref. D4 OM-246 691 Page 16
A. Connecting 1-Phase Input Power (Continued)! Installation must meet all National and Local Codes have only qualified persons make this installation.! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site. 1 Input Power Cord 2 Disconnect Device (switch shown in the OFF position) 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals 5 Black And White Input Conductor (L1 And L2) 6 Green Or Green/Yellow Grounding Conductor Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 7 Over-Current Protection Select type and size of over-current protection using Section 4-5 (fused disconnect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service. input4 2012 05 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-246 691 Page 17
B. 3-Phase 3 = GND/PE Earth Ground 4 7 2 3 6 L1 L2 L3 5 1 Tools Needed: input2 2012 05 Ref. D5 OM-246 691 Page 18
B. Connecting 3-Phase Input Power (Continued)! Installation must meet all National and Local Codes have only qualified persons make this installation.! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site. For Three-Phase Operation 1 Input Power Cord. 2 Disconnect Device (switch shown in the OFF position) 3 Green Or Green/Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors (L1, L2 And L3) 6 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1, L2, and L3 to disconnect device line terminals. 7 Over-Current Protection Select type and size of over-current protection using Section 4-5 (fused disconnect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service. input2 2012 05 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-246 691 Page 19
4-7. Installing Drive Rolls And Wire Guide 2 1 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Drive Roll The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread. 4 Drive Roll Securing Screw Tighten screw to secure drive roll. 3 4 Tools Needed: 2.5 mm 956142721_2-2 Notes OM-246 691 Page 20
4-8. Threading Welding Wire And Adjusting Pressure Roll Tension 4 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 7 1 Tools Needed: 2 3 5 6 Hold wire tightly to keep it from unraveling. 150 mm (6 in.) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Tighten Use pressure indicator scale to set a desired drive roll pressure. 1 2 3 4 Pressure Indicator Scale Close and tighten pressure assembly, and let go of wire. Remove gun nozzle and contact tip. Turn On. Tighten WOOD 1 2 3 4 Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close and latch door. 956142715_3-5/956142715_4-5 OM-246 691 Page 21
5-1. Controls For MigMatic 220/250 SECTION 5 OPERATION 5 4 3 2 1 1 Power Switch S1 Use switch to turn power on and off. 2 Voltage Control S2 Turn control clockwise to increase voltage. 3 High Temperature Shutdown Light PL2 (Orange LED) 4 Power Indicator Light PL1 (White LED) 5 Wire Feed Speed Control R1 Turn control clockwise to increase wire feed speed. 6 MIG Torch Connection Connection for Euro style MIG gun. 7 Work Lead Connection 6 7 956142715_5-5 5-2. Burnback And Spot Weld Timer Controls 1 2 1 Burnback Control R3 Time that welding wire stays energized after trigger is released. 2 Spot Weld Timer R2 Time that welding arc is active before shutting off automatically. Spot Timer resets after releasing gun trigger. 956142715_3-5 OM-246 691 Page 22
5-3. Controls For MigMatic 220 DX / 250 DX 5 10 8 11 12 4 9 6 7 3 1 2 14 13 1 Power Switch S1 Use switch to turn power on and off. 2 Voltage Control S2 Turn control clockwise to increase voltage. 3 High Temperature Shutdown Light PL2-(Orange LED) 4 Power Indicator Light PL1 (White LED) 5 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 (See Section 5-5) 6 MIG Torch Connection Connection for Euro style MIG gun. 7 Work Lead Connection 8 Spool Gun Connection 7-pin Plug Receptacle 9 Digital Display Meter Displays values and parameters for selected welding process 10 Setup Button Use button to select parameters (V, A, %), and to change from manual to synergic MIG modes. 11 Trigger Mode Button Use control to select desired trigger mode (see Section 5-7). 12 Wire Diameter Push Button Use control to Select desired welding wire diameter for synergic MIG process (see Section 5-9). 13 Material Button Use control to select material type for synergic MIG process (see Section 5-10). 14 Gas Selection Button Use control to select desired welding gas type for synergic MIG process (see Section 5-11). 956142718_5-5 5-4. Burnback And Spot Weld Timer Controls 1 2 1 Burnback Control R3 Use control to set time welding wire stays energized after trigger is released. 2 Wire Run-In Speed Control R2 Use control to determine rate at which welding wire feeds before an arc is initiated. 956142718_4-5 OM-246 691 Page 23
5-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only) 1 2 3 4 5 6 7 9 8 1 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 2 Wire Feed Speed Indicator Scale (Manual Mode) 3 Input Line Voltage Adjustment Center Indicator (Synergic Mode) 4 Input Line Voltage/Wire Speed Adjustment Indicator Scale (Synergic Mode) Before power up, turn control R1 to the center position. Within 5 seconds of power up, unit verifies value of input line voltage, and if necessary, makes correction based on a percentage of preset (synergic) parameters. 5 Power Indicator Light PL1 6 Digital Meter Display The required type of input voltage correction (plus or minus) is displayed on digital meter as follows: 7 Negative Percentage Input Line Voltage Adjustment Display Indicator A dash in the left segment of the meter and a flashing PL1 indicates the need for a negative correction. Turn R1 counterclockwise to decrease value. 8 Positive Percentage Input Line Voltage Adjustment Display Indicator A dash in the right segment of the meter and a flashing PL1 indicates the need for a positive correction. Turn R1 clockwise to increase value. 9 Correct Input Line Voltage Display Indicator A dash in the center segment of the meter indicates the input voltage is correct. Input line voltage compensations are made each time the unit is turned on. Fluctuations in input line voltage that occur more than five seconds after power up are not automatically compensated for. The operator must manually adjust for incorrect input line voltage by rotating control R1. Correct adjustment is confirmed by a beeping or buzzer signal, while a flashing power indicator light PL1 indicates an incorrect input line voltage. While PL1 is flashing, the machine will continue to operate, but weld output characteristics may be affected. After correct input line voltage has been established, 220 or 250 (depending on model) is displayed on the meter. Each time the machine is turned on, the last setting is displayed OM-246 691 Page 24
5-6. Welding Power Source Setup Menu (DX Models Only) 1 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 2 Synergic Mode Indicator 3 Voltage LED 2 3 4 5 6 7 8 9 4 Digital Display Meter 5 Amperage LED 6 Wire Feed Speed LED 7 Setup Button 8 Manual Mode Indicator 1 9 Voltage Control 10 Trigger Mode Button Use setup button to select desired parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %). Rotate Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control to change wire feed speed or amperage, depending upon which parameter is active. Rotate voltage control to change voltage when voltage LED is lit. 10 The value of the selected parameter is displayed on display meter. The default for preset wire feed speed is meters per minute. To change to inches per minute, press and hold setup and trigger function buttons for approximately 5 seconds. Selecting Manual Or Synergic Mode Press and hold setup button for approximately 3 seconds to switch between manual mode (see Section 5-12) and synergic mode (see Section 5-13), and lite corresponding mode indicator LED. OM-246 691 Page 25
5-7. Trigger Mode Selection (DX Models Only) 1 2 4 3 Always select a trigger mode. 1 2T Trigger Mode When trigger is pressed welding starts. When trigger is released, welding stops. 2 4T Trigger Mode When trigger is pressed, welding starts. When trigger is released, welding continues. When trigger is pressed and released a second time, welding stops. 3 Trigger Mode Selection Button Press button to select desired trigger mode and lite corresponding LED. 2T and 4T trigger methods work in both manual and synergic modes. 4 Spool Gun Mode (See Section 5-8) 5-8. Spool Gun Mode (DX Models Only) 1 1 Spool Gun Mode Indicator LED Connect spool gun to 7-pin spool gun receptacle (see Section 5-3). With spool gun connected and power source in the manual mode, the manual mode indicator LED is lit (see Section 5-6), and wire feed speed is controlled with the potentiometer on the spool gun. While in the synergic mode, the synergic mode indicator LED is lit. Use only aluminum welding wire in the synergic mode. When spool gun is connected, 2T and 4T trigger modes are disabled. For 2T and 4T trigger operation, see Section 5-7. OM-246 691 Page 26
5-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only) 1 Welding Wire Diameters 2 Welding Wire Diameter Button Press button to select desired wire diameter: 0.6 mm, 0.8 mm, 1.0 mm, or 1.2 mm, and lite corresponding LED. 1 2 5-10. Welding Wire Type Selection For Synergic MIG (DX Models Only) 1 Welding Wire Types 2 Welding Wire Type Button Press button to select desired wire type: Fe (ferris), CrNi (stainless steel), Al (aluminum), or CuSi (Copper Silicon), and lite corresponding LED. 1 2 5-11. Gas Selection For Synergic MIG (DX Models Only) 1 Shielding Gas Types 2 Gas Selection Button Press button to select desired shielding gas type: CO 2 (Carbon Dioxide), Mix (ArCO 2 ), Arg (Argon), and lite corresponding LED. 1 2 OM-246 691 Page 27
5-12. Selecting Manual MIG Welding (DX Models Only) 6 4 5 1 2 3 1 Setup Button 2 Manual MIG Mode Indicator Press and hold setup button for approximately 3 seconds to select manual MIG mode and lite indicator. 3 Voltage Control S2 4 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 5 Digital Display Meter In Manual MIG mode, the operator may need to adjust main welding parameters for specific arc characteristics Use setup button to select desired parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %). The value of the selected parameter is displayed on meter. Turn voltage control clockwise to increase voltage. Turn wire feed speed control clockwise to increase wire feed speed. Select trigger mode 2T or 4T according to Section 5-7. Spool Gun Operation: 6 Spool Gun Receptacle For spool gun connection and operation, see section 5-8. OM-246 691 Page 28
5-13. Selecting Synergic MIG Welding (DX Models Only) 1 Setup Button 2 Synergic MIG Mode Indicator 4 2 5 1 3 Press and hold Setup button for approximately 3 seconds to select synergic MIG mode and lite indicator. 3 Voltage Control S2 4 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 5 Digital Display Meter In synergic MIG mode, the operator may have to adjust welding data for specific arc characteristics. Generally voltage is adjusted and the synergic process automatically sets appropriate wire feed speed. 10 Use setup button to select desired parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %). The value of the selected parameter is displayed on meter. Turn voltage control S2 clockwise to increase voltage. Turn wire feed speed control R1 clockwise to increase wire feed speed. 6 Trigger Mode Button 6 7 8 9 Use button to select 2T or 4T (see Section 5-7). 7 Wire Diameter Button Use button to select desired wire diameter. 8 Welding Wire Type Button Use button to select appropriate welding wire type. 9 Gas Selection Button Use button to select desired shielding gas. Spool Gun Operation: 10 Spool Gun Receptacle For spool gun connection and operation, see section 5-8. OM-246 691 Page 29
SECTION 6 MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance! Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Blow out or vacuum inside. OR Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft. 6-2. Circuit Breaker CB1 1 2 1 Circuit Breaker CB1 CB1 protects the unit from overloading of drive motor M1. If CB1 opens, wire feeding stops. 2 Welding Gun Check gun liner for blockage or kinks. 3 Wire Drive Assembly Check for jammed wire, binding drive gear or misaligned drive rolls. Allow cooling period and reset breaker. Close door. 3 6-3. Unit Overload Thermal switches TP1 in SR1 and TP2 in XFMR protect the unit from damage due to overheating. If the thermal indicator illuminates, wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact Factory Authorized Service Agent. OM-246 691 Page 30